Support for solar energy collection

ABSTRACT

A solar energy collection system can include support devices made with bearings. Such bearings can include an inner partially toroidal surface for sliding contact and support of an outer surface of a torque tube. The toroidal surface can be made with a single radius of curvature or multiple radiuses of curvature and cylindrical portions. The bearings can include connectors for connecting the bearing members to a support housing. The connectors can be tool-less connectors.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/799,625 filed Mar. 15, 2013, the entire contents of which are herebyincorporated by reference.

TECHNICAL FIELD

The inventions disclosed herein generally relate to solar energy systemswhich include supports for solar energy collection collecting devices.

BACKGROUND

Some larger solar collector installations include an array ofsun-tracking, solar power collector assemblies. Such assemblies can beused in conjunction with photovoltaic modules, concentrated photovoltaicmodules, as well as concentrated thermal solar collector devices.

Such sun-tracking collectors include hardware for automaticallyadjusting the position of the collector devices to track the sun as itmoves across the sky. This tracking movement can be accomplished in anumber of different ways. Some systems use a single axis tracking systemin which the collector devices pivot about a single axis. Such singleaxis type tracking systems often include a drive shaft or “torque tube”which defines a single pivot axis. Other systems use multiple axes ofrotation.

Because the torque tubes pivot through a limited range of rotation aboutthe axis, conventional roller bearings are not necessary for suchapplications; they would be an unnecessarily large expense for such anapplication. Thus, some sun-tracking solar systems include other typesof bearings.

BRIEF SUMMARY

An aspect of at least one of the inventions disclosed herein includesthe realization that bearings for sun-tracking solar energy collectionsystems can be simplified while also for accommodating misalignment thatcan be caused during installation. For example, some bearings used tosupport torque tubes of a sun-tracking solar collection system requirethat the pivot axis of the torque tube be precisely aligned with therotational axis of the bearing. This can be a difficult alignment toachieve during installation because the components of sun-tracking solarsystems can be quite large and heavy.

Thus, in accordance with at least one of the embodiments disclosedherein, a sun-tracking photovoltaic solar collector array can comprise aplurality of photovoltaic devices. A support assembly can support thephotovoltaic devices so as to be pivotable about a pivot axis. Thesupport assembly can comprise at least a first pivot supporting theplurality of photovoltaic modules, at least a first bearing supportingthe first pivot so as to be pivotable about the pivot axis and at leastone pier supporting the bearing at a position above the support surface.The bearing comprising an inner surface that is at lease partiallytoroidal.

In accordance with another embodiment a sun-tracking photovoltaic solarcollector array can comprise a plurality of photovoltaic devices. Asupport assembly can support the photovoltaic devices so as to bepivotable about a pivot axis. The support assembly can comprise at leasta first pivot supporting the plurality of photovoltaic modules andhaving an outer surface. At least a first bearing can support the firstpivot so as to be pivotable about the pivot axis. At least one pier cansupport the bearing at a position above a support surface. The bearingcan comprise at least a first reduced friction member comprising aninner surface positioned so as to slide against the outer surface of thepivot when the first pivot pivots about the pivot axis, the innersurface being at least partially toroidal.

In accordance with yet another embodiment a bearing assembly cancomprise a bearing housing. The bearing housing can have a fixtureportion configured to be secured so as to be fixed relative to theground. The bearing housing can further comprise at least a firstbearing seat configured to support the first bearing member. A firstbearing member can have an outer surface adapted to be supported by thebearing seat and an inner surface configured to slidably support ashaft, the inner surface being at least partially toroidal.

An aspect of at least one of the inventions disclosed herein includesthe realization that material and/or manufacturing costs for certainsolar system components can be further reduced by adoptingconfigurations based on minimized modification of raw materialconfigurations that are widely available.

For example, some known designs for piles of sun tracking solar energycollection systems include the use of channel-shaped structural steel.In order to provide better balance against the inherent torsionalloading of a channel caused by a perpendicular load aligned with the webof the channel, some designs include a mounting surface offset from theplane of the web of the channel member so as to reduce or eliminate thereactionary torsional loading noted above.

Certain mounting configurations for reduced friction assemblies thatinclude a convex partially toroidal surface can be manufactured usingknown techniques by curling over a longitudinal end of a structuralmember having a substantial sheet shaped portion, such as the web of achannel member. However, forming a bearing support on the web of achannel member, when subject to direct lateral forces in a directionparallel to the web, would creating an undesired reactionary torsionalloading of the beam.

Thus, in accordance with at least one embodiment, a support for a solarenergy collection system can comprise a generally vertically extending,fixed, support member, the support member comprising a generallyvertically extending sheet portion having first and second lateral edgesthat also extend generally vertically, first and second lateralportions, extending outwardly from the left and right lateral edges, andforming a generally symmetrical cross-section of the substantiallyvertical support member. An upper edge of the sheet portion can includea support surface portion extending along an at least partially toroidalshape, a reduced friction member supported by the at least partiallytoroidally shaped surface, and at least a first cap member fixedrelative to the first support member and extending over so as togenerally encircle, along with the first reduced friction surfacemember, the outer surface of the torque tube.

In some embodiments, the first generally vertical support member can beI-beam shaped, or S-beam shaped.

Another aspect of at least one of the inventions disclosed hereinincludes the realization that the structural components forming theupper half of bearing assemblies that support the main pivoting supportmembers, such as torque tubes, are loaded far less often compared to theportions supporting the lower part of the bearings, to such an extentthat the upper portion of the reduced friction assembly can be formedwith a less robust, and thus less costly, without excessivelycompromising performance of the system.

For example, in some embodiments, a reduced friction assembly caninclude a lower, rigidly fixed support member made from a firstmaterial, a first lower reduced friction member supported by the lowersupport member, and an upper reduced friction member having a bearingsurface extending along at least a partially toroidally shaped surface,the upper reduced friction member comprising a material that generates acoefficient of friction with galvanized steel that is lower than thecoefficient of friction generated at a galvanized steel to galvanizedsteel sliding contact; wherein no additional structural member extendsaround an outer portion of the upper reduced friction member.

The upper member can be made from a fiber reinforced composite material,having a matrix made from a plastic material such as an ultra highdensity polyethylene, or other reduced friction materials impregnatedwith a fiber such as carbon fiber, fiberglass, or other fibers.

By using a fiber matrix composite material for the upper portion, theupper portion can conveniently be formed with a reduced friction outersurface, primarily formed by the matrix of the material, yet provideanti-catastrophic failure benefits, as well as other benefits, of fiberreinforcement. This can be beneficial because while the upper bearing orreduced friction members are rarely loaded, strong gusts of wind cansuddenly and repeatedly cause net lift forces, created by winds flowingover and around solar modules. If the upper bearing members were madeentirely from non-reinforced plastic, they could break morecatastrophically and rapidly; failure mechanisms characterized by morebrittle materials.

However, fiber reinforced materials, such as fiber-matrix compositematerials, fail more gradually; cracks formed through a matrix can leavemany of the fibers in place, but possibly loosened. In this condition, acomponent made from such a material can continue to withstandconsiderable loads, but might not provide optimal friction performanceduring subsequent use. Such components can be inspected for damage andreplaced. However, if a plurality of such upper bearing memberscatastrophically fail during a wind event, a torque tube could be liftedoff of one or more of its vertical supports causing significant damageto the solar modules. Thus, forming the upper bearing member with afiber reinforced composite material having a reduced friction matrix,allows the upper bearing members to have a simplified construction,integrating both structural strength and reduced friction, themanufacture and construction of such a system can be further reduced.

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the detaileddescription. This summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the subject matter may be derived byreferring to the detailed description and claims when considered inconjunction with the following figures, wherein like reference numbersrefer to similar elements throughout the figures.

FIG. 1 is a schematic top plan view of a solar collector system;

FIG. 2 is a schematic diagram of the system illustrated in FIG. 1including optional electrical connections of the collector system withvarious electrical components;

FIG. 3 is a perspective view of a non-concentrated photovoltaicembodiment of the solar collection system of FIG. 1, illustrating aplurality of piers mounted to the ground and supporting a plurality oftorque tubes, in which the present bearing can be used;

FIG. 4 is a schematic side elevational view of a solar collectorassembly for a concentrated photovoltaic embodiment of the solarcollection system of FIG. 1, in which the present bearing can also beused;

FIG. 5 is a perspective view of the embodiment of FIG. 4 and including asun-tracker drive;

FIG. 6 is an exploded view of a bearing assembly in accordance with anembodiment having upper and lower bearing members and upper and lowerbearing housing portions;

FIG. 7 is a top plan view of a lower portion of the housing and thelower bearing member illustrated in FIG. 6;

FIG. 8 is a sectional view of the assembled housing illustrated in FIG.6 as viewed along the line 8.-8. of FIG. 7;

FIG. 9 is an enlarged plan view of the lower bearing member illustratedin FIG. 6;

FIG. 10 is a perspective view of the bearing member illustrated in FIG.9;

FIG. 11 is a perspective view of another embodiment of the bearingassembly illustrated in FIG. 9;

FIG. 12 is an exploded perspective view of the embodiment of FIG. 11;

FIG. 13 is a sectional view of a lower portion of the embodiment of FIG.11 with upper and lower bearing members removed;

FIG. 14 is a top plan view of the embodiment of FIG. 11 with the topbearing member and top support member removed;

FIG. 15 is an exploded perspective view of another embodiment of thebearing assembly of FIG. 6 having an integrated upper bearing member andhousing portion;

FIG. 16 is an exploded and perspective view of the bearing assemblyillustrated in FIG. 15;

FIG. 17 is an enlarged exploded perspective view of bearing assembly ofFIG. 16; and

FIG. 18 is an enlarged perspective view of an integrated upper bearingmember of the bearing assembly of FIGS. 15-17.

DETAILED DESCRIPTION

The following detailed description is merely illustrative in nature andis not intended to limit the embodiments of the subject matter or theapplication and uses of such embodiments. As used herein, the word“exemplary” means “serving as an example, instance, or illustration.”Any implementation described herein as exemplary is not necessarily tobe construed as preferred or advantageous over other implementations.Furthermore, there is no intention to be bound by any expressed orimplied theory presented in the proceeding technical field, background,brief summary, or the following detailed description.

Certain terminology may be used in the following description for thepurpose of reference only, and thus are not intended to be limiting. Forexample, terms such as “upper”, “lower”, “above”, and “below” refer todirections in the drawings to which reference is made. Terms such as“front”, “back”, “rear”, and “side” describe the orientation and/orlocation of portions of the component within a consistent but arbitraryframe of reference which is made clear by reference to the text and theassociated drawings describing the component under discussion. Suchterminology may include the words specifically mentioned above,derivatives thereof, and words of similar import. Similarly, the terms“first”, “second”, and other such numerical terms referring tostructures do not imply a sequence or order unless clearly indicated bythe context.

The inventions disclosed herein are described in the context ofnon-concentrated and concentrated photovoltaic arrays and modules.However, these inventions can be used in other contexts as well, such asconcentrated thermal solar systems, etc.

In the description set forth below, a solar energy collection system 10is described in the context of being formed by a plurality of solarcollection modules, pivotally adjusted for sun-tracking purposes by adrive. Each of the modules can include a support member supporting aplurality of solar collection devices, which can be concentrated ornonconcentrated solar collection devices as well as wiring forconnecting the various solar collection devices to each other and toother modules.

The system 10 can also include devices for reducing labor, hardware, orother costs associated with installing such a system. Specifically, forexample, a sun-tracking solar energy collection system can includebearing assemblies that include one or more features designed to reducethe cost of manufacture and/or installation of such bearings.

FIGS. 1-4 illustrate different environments in which the inventionsdisclosed herein can be used. FIG. 1 is a schematic illustration of asolar collection system 10, which can be considered an electricity farmoperating under a concentrated or non-concentrated principle.

The solar collection system 10 can include a solar collector array 11which includes a plurality of solar collection modules 12. Each of thesolar collection modules 12 can include a plurality of solar collectingdevices 14 supported by a drive shaft or torque tube 16. Each of thetorque tubes 16 are supported above the ground by a support assembly 18.Each of the support assemblies 18 can include a bearing assembly 20. Assuch, the torque tubes 16 can be considered as pivots supporting themodules 12.

With continued reference to FIG. 1, the system 10 can also include atracking system 30 connected to the torque tubes 16 and configured topivot the torque tube 16 so as to cause the associated collector devices14 to track the movement of the sun. In the illustrated embodiment, thetorque tubes 16 are arranged generally horizontal and the modules 12 areelectrically connected to each other, as more fully described in U.S.patent application Ser. No. 13/176,276, filed Jul. 5, 2011, the entirecontents of which is hereby expressly incorporated by reference. Thetracking system can include a single motor and drive components adaptedto drive a plurality of parallel torque tube assemblies (e.g.,assemblies comprising a series of axially aligned torque tubes connectedend-to-end), or a plurality of motors, each connected one or a pluralityof axially aligned torque tubes 16.

Optionally, the system 10 can include a plurality of modules 12supported by torque tubes 16 that are inclined relative to horizontal,wherein the torque tubes 16 are not connected in an end to end fashion,such as the arrangement illustrated and disclosed in U.S. PatentPublication No. 2008/0245360. The entire contents of the 2008/0245360patent publication is hereby expressly incorporated by referenceincluding the illustrations and the descriptions of the bearings 40 and72. Further, the inventions disclosed herein can be used in conjunctionwith the systems that provide for controlled tilting about two axes,although not illustrated herein.

The solar collection devices 14 can be in the form of photovoltaicpanels, thermal solar collection devices, concentrated photovoltaicdevices, or concentrated thermal solar collection devices.

With reference to FIG. 2, the solar collection system 10 can furtherinclude an electrical system 40 connected to the array 11. For example,the electrical system 40 can include the array 11 as a power sourceconnected to a remote connection device 42 with power lines 44. Theelectrical system 40 can also include a utility power source, a meter,an electrical panel with a main disconnect, a junction, electricalloads, and/or an inverter with the utility power source monitor. Theelectrical system 40 can be configured and can operate in accordancewith the descriptions set forth in U.S. patent application Ser. No.12/371,315, to Peurach et al., published as U.S. Patent Publication No.2010/0071744, and entitled “Photovoltaic Installation with AutomaticDisconnect Device.” the entire contents of which are hereby expresslyincorporated by reference in its entirety for all purposes.

FIG. 3 illustrates a non-concentrated photovoltaic, sun-trackingembodiment of the array 11 with all but one of the solar collectiondevices 14 removed. As shown in FIG. 3, each of the support assemblies18 includes the bearing 20 supported at the upper end of a pier 22. Thetorque tube 16 can be of any length and can be formed in one or morepieces. The spacing of the piers 22 relative to one another, can bedetermined based on the desired limits on deflection of the torque tubes16 between the support structures 18, wind loads, and other factors.

The tilt drive 30 can include a drive strut 32 coupled with the torquetube 16 in a way that pivots the torque tube 16 as the drive strut 32 ismoved axially along its length. The drive strut 32 can be connected withthe torque tube 16 with torque arm assemblies 34. In the illustratedembodiment, the torque arm assemblies 34 disposed at an end of each ofthe torque tube 16. Additionally, the array 11 can include an electricalwire tray 60 supported by one or more of the piers 22, or by othermeans.

FIGS. 4 and 5 illustrate components of a concentrated photovoltaic,sun-tracking embodiment of the array 11. For example, as schematicallyshown in FIG. 4, a concentrated photovoltaic solar assembly 100 caninclude a pile 102 which supports one or more cross beams 104 and atorque tube 106. The cross beam 104 in turn supports first and secondgroups of concentrating elements 120, 140, supported by the cross beam104.

In the illustrated embodiment, one group of concentrating elements 120face in one direction and the second group of concentrating elements 140are positioned so as to face the opposite direction, with the changeoverbetween them occurring at the torque tube 106. The pier 102 can be asingle post or one of several supporting the solar concentrator assembly100.

Connectors 150 support the concentrator elements 120, 140 relative tothe cross beam 104. Additionally, photovoltaic collectors 132, 134, 152,154 can be mounted on the back sides of the concentrator elements 120,140. In this configuration, each of the concentrator elements 120, 140are configured to focus a band of concentrated light onto thephotovoltaic units 132, 134, 152, 154. A sun-tracking drive system 200can drive the torque tube 16 to pivot about the pivot axis A. Furtherdetail regarding the optional configuration of a concentratedphotovoltaic environment of use is set forth in U.S. patent applicationSer. No. 12/977,006 filed Dec. 22, 2010, the entire contents of which ishereby incorporated by reference.

The bearings 20 can be supported directly on piers 102 described abovewith reference to FIGS. 1-4. Optionally, the bearing assemblies 20 canoptionally be supported by piers 200 (FIG. 6). The piers 200 can be inthe form of structural channel members, such as steel channel that iswidely commercially available. Such piers 200 can include a web portion202 and flanges 204, 206. Optionally, the pier 200 can includeadditional inwardly extending flanges 208, 210. Such piers 200 can bepile driven into the ground and/or further secured with cementfoundations.

During installation of such piers 200, the pile driving process and/orcreation of foundations can cause the piers 200 to be misaligned, eitheras to their height, lateral, and parallel alignment relative to therotational axes A of the torque tubes 16.

Thus, the piers 200 can include oval apertures 212, 214 to accommodateat least some of the misalignment that can occur in the installation ofthe piers 200. Other pier designs can also be used. For example,aperture 212 can be a round hole and aperture 214 can be a horizontallyextending oval or slot.

With reference to FIGS. 6-8, an embodiment of a bearing assembly 20 isillustrated therein. It is to be noted that in a solar energy collectionsystem 10, there may be many bearings supporting each of the torque tube16. However, one bearing assembly 20 is illustrated and described hereinwith the understanding that many such bearing assemblies 20 can be usedthroughout the system 10.

The bearing assembly 20 can include a bearing housing assembly 220 and abearing member assembly 222.

The bearing housing 220 can be made from one or more parts connectedtogether. For example, the bearing housing 220 can include a lowerhousing portion 224 and an upper housing portion 226.

The lower portion 224 of the housing 220 can include a fixture portion230 configured to be securely connected to a pier, such as the pier 200.In the illustrated embodiment, the fixture portion 230 includes two slotshaped apertures 232, 234 sized to accommodate threaded fasteners (notshown) which can pass through the apertures 232, 214, 234, and 212 tothereby secure the fixture portion 230 to the pier 200. Additionally,the slot shape of each of the apertures 212, 214, 232, 234 allows thefixture portion 230 to be fixed to the pier 200 with a range ofpositions so as to allow an installer, after the pier 200 is fixed toground surface, to adjust the position of the fixture so as to achievethe desired alignment of the bearing assembly 20 with the desiredlocation of a torque tube 16, including, optionally, both up and downadjustments as well as lateral adjustments, i.e., left and right.

Optionally, the fixture portion 230 can include a generally planar faceportion 240 configured to lie flat against the web portion 202 of thepier 200. The apertures 232, 234 can be provided in the face portion240.

The lower portion 224 of the housing 220 can also include a bearing seatportion 250. The bearing seat portion 250, optionally, can be configuredto support a portion of a bearing member. For example, the bearing seatportion 250 can be configured to extend around and support a portion ofa bearing member so as to support at least about one-third to aboutone-half of a bearing member from below.

This can provide a further advantage in that when a solar energycollection system 10 is being installed, the lower portion 224 of thehousing can be fixed in place, along with a portion of a bearing member,and then the torque tubes 16 can be lowered down onto the lower portion224 on an associated bearing member. Then, the remaining portion of thebearing assembly 20 can be completed. This is convenient because torquetube assemblies can be quite long and heavy.

In the illustrated embodiment, the bearing support portion 250 isgenerally semi-circular and extends around about a 180 degree arc, asillustrated in FIG. 8. Other configurations can also be used.

In the configuration where the lower portion 224 extends around about180 degrees of a central axis B of the bearing assembly 20, the upperportion 226 can also include a bearing seat having a complimentary shapeto provide a seat extending around the full 360 degrees around the axisA, described in further detail below.

The seat 250 can include a center line that is generally offset from theface 240. For example, as shown in FIG. 7, the center line 252 of theseat 250 can be spaced apart by a distance 254. This offset can behelpful in balancing loads imparted onto the pier 200. For example, whenusing a pier such as the pier 200 which has a C channel configuration,offsetting the centerline of the bearing seat 250 from the web 202 canhelp balance the reactionary forces caused by the pier 200 when thebearing assembly 220 is subjected to lateral loads (i.e., loads that areperpendicular to the axis A). For example, as is well known in the art,when a channel beam is subjected to a lateral load, i.e., perpendicularto its webs and directed toward a point within the cross-section of theC-shape, such a force can result in a torsional load on the beam basedon the moment of inertia of the beam. Thus, by offsetting the centerline 252 (FIG. 7) of the bearing seat 250 away from the web 202 (FIG.6), the resulting load on the pier 200 can be more of a pure bendingload, which can thereby prevent the bearing seat 250 from being twistedrelative to the axis A (i.e., twisted about an axis that extendsgenerally vertically as viewed in FIG. 6). The spacing 254 can becalculated based on known techniques.

The lower portion 224 can also include lateral flanges that extend fromthe lower end of the fixture portion 230 up to the upper end of thelower portion 224. The flanges are identified by the reference numerals256, 258. The size of the flanges 256, 258 as well as the face portion240 and the bearing seat 250 can be chosen to provide the desiredstiffness.

The upper end of the lower portion 224 can include apertures 260 thatcan be used for securing the lower portion 224 to the upper portion 226.

The upper portion 226 can also include, at its lower end, apertures 260positioned and spaced so as to align with the apertures 260 in the lowerportion 224, when the upper and lower portions 226, 224 are broughttogether in the orientation illustrated in FIG. 8.

The upper portion 226 can also include a bearing seat portion 262 thatextends around the axis B, (when in the position illustrated in FIG. 8)so as to compliment the seat 250 of the lower portion 224 and to providesupport for the bearing members 222.

In the illustrated embodiment, the bearing seats 250, 262 have agenerally C-shaped cross-section (as illustrated in FIG. 7). In theillustrated embodiment, the inner surface 264 of the bearing seat 250and the inner surface 266 of the bearing seat 262 have a partiallytoroidal shape, more specifically, the portion of a toroid around thecentral aperture of a toroid. However, other shapes can also be used.

Additionally, the bearing seats 250, 262 can be made in otherproportions. For example, the lower portion 224 can have a bearing seat250 that extends only about 90 degrees about the axis A and the upperportion can include one or pieces extending over the remaining 360degrees around the axis A. Similarly, the lower portion 224 can includea bearing seat 250 that extends around about 120 degrees, with the upperportion 226, made in one or more parts, extending around the remaining240 degrees around the axis A. Additionally, the bearing seats 250, 262can be noncontinuous, i.e., they can be formed in only segments withgaps between them extending around the axis A. Other configurations canalso be used. Further, the inner surfaces 264, 266 can be shaped tocompliment the outer surface of the bearing members 222. Thus, if thebearing members 222 have outer surfaces that are different than in theillustrated embodiments, the outer surfaces 264, 266 can have differentconfigurations.

With reference to FIGS. 7, 9, and 10, the bearing members 222 can beformed from one or more pieces. In the illustrated embodiments, thebearing members 222 each extend around about 180 degrees around the axisB. The bearing members 222, however, can be made in other sizes. Thebearing members 222 are made from a material that provides reducedsliding friction against the outer surface of the torque tubes 16. Thus,the bearing members 222 can be considered as reduced friction members.For example, the bearing members 222 can be made from any material,including ultra high molecular weight polyethylene (UHMWPE) plasticmaterial. However, other materials can also be used, such as greasesoaked cotton, wood, Delrin, Nylon, Polyethylene, Polyurethane,Polytetrafluoroethylene, Brass, Polystyrene, Polyoxymethylene,Acrylonitrile butadiene styrene, Polyamide, or Polyphenylene Oxide,other plastics, or other materials.

With the illustrated design, as well as with other designs, the upperand lower bearing members 222 can all be identical in shape. Thus, onlyone of the bearing members 222 will be described in detail below.

With continued reference to FIGS. 9 and 10, the bearing members 222 canhave a generally C-shaped cross-section, and when brought together asshown in FIG. 8, provide a substantially fully circular, partiallytoroidal, bearing surface. In the illustrated embodiment, the bearingsurface can be considered the inner surface 270 of the bearing members222. The inner surface 270 can have a single radius of curvature ormultiple radii of curvature. In the illustrated embodiment, the surface270 includes outer portions 272, 274 having a single radius of curvatureand a central portion 276 that is generally cylindrical, i.e., itscross-section is not curved. In some embodiments, the width 278 of thecentral portion 276 of the inner surface 270 can have a width of aboutone-quarter to one-half inch. Other sizes can also be used.

The bearing members 222 can also include an outer surface 280. The outersurface 280 can be shaped and configured to cooperate with the outersurfaces 264, 266 of the bearing seats 250, 262 (FIG. 8). The partiallytoroidal shape of the seats 250, 262 and the complimentarily-shaped,partially toroidal shape of the outer surface 280 of the bearing members222 can provide particular advantages in the environments of usedisclosed above.

For example, these cooperating partially toroidal surfaces can beconfigured to cooperate to maintain the bearing members 222 in thedesired position against longitudinal loads that may be applied totorque tubes extending through the assembled bearing assembly 20 (asillustrated in FIG. 8), such as forces extending parallel to the axis A,while at the same time providing adequate support for supporting theweight of torque tubes normally supported by the lower portion 224 andthe lowermost bearing member 222. However, the upper bearing member 222and the upper portion 226 of the housing assembly 220 also work toretain the torque tube 16 between the bearing members 222 when thetorque tubes experience uplift, for example, caused by aerodynamicforces on the photovoltaic devices 12 (FIG. 1).

Optionally, the bearing assemblies 20 can include connectors forsecuring the bearing member 222 to one or both of the lower and upperportions 224, 226. As such, the bearing member 222 can be better held inplace during a procedure for assembling the solar energy collectionsystem 10. For example, as noted above, during the construction of thesystem 10, the piers 200 are secured to a ground, by either a piledriving and/or cement foundations. Then, the lower portion 224 of thehousing 220 is secured to the pier 200. Then, one bearing member 222 issecured to the bearing seat 250 of the lower portion 224.

In this configuration, torque tube 16 can be lowered down onto all thepartially assembled bearing assemblies 20 throughout the system 10. Asthe torque tubes are lowered onto the bearing members 222, it ispossible that the torque tube will be pressed against one side of abearing member 222. For example, as reflected by the arrow 290 of FIG.8. Such an unbalanced force against the bearing member 222 can cause thebearing member to slide in an arcuate direction, along the arrow 292. Ifthis type of sliding occurs, the bearing member 222 can be dislodgedfrom its seat 250 and thereby require additional adjustments to thepositioning of the bearing member 222 before the bearing assembly 220can be fully assembled. Thus, adding a connector for connecting thebearing member 222 to the lower portion 224 of the housing 220 canprovide an additional benefit in preventing movement of the bearingmember 222 during such an installation procedure.

In some embodiments, a connector can be in the form of protrusions 294,296 on the outer surface 280 of the bearing members 222. The protrusions294, 296 can be configured to cooperate with apertures 298, 300 formedon the bearing seat 250 (FIG. 8). In the illustrated embodiment, theprotrusions 294, 296 are in the shape of ramped protrusions that areconfigured to provide a snap fit with the apertures 298, 300,respectively. As such, the bearing 222 can be connected to the bearingseat 250 without any tools. In other words, the protrusions 294, 296 andthe apertures 298, 300 cooperate to provide a tool-less connection.Further, the protrusions 294, 296 and the apertures 298, 300 cancooperate with the partially toroidal shapes of the outer surface 280(FIG. 10) of the bearing members 222 and the partially toroidal shapesof the inner surfaces 264, 266 of the bearing seats to capture thebearing member 222 in the desired position, so as to resist movement,both in axial and circumferential directions.

Similarly, the upper portion 226 can also include similar apertures onits outer surface 266 so as to cooperate with the protrusions 294, 296on the bearing member 222. Such connections can further simplify aninstallation procedure.

With continued reference to FIG. 8, the bearing members 222 and thehousing 220 can be sized so as to provide a clearance 304 between theouter surface of a torque tube and the inner surface 270 of the bearingmembers 222. For example, where the torque tube 16 has an outer diameterof approximately 127 millimeters, the clearance 304 can be approximately2.25 millimeters. As such, the inner diameter defined by the innersurface of the central portion 278 of the inner surface 270 of thebearings 222 can be approximately 4.5 millimeters greater than the outerdiameter of the torque tube 16. However, other clearances can also beused.

Using a clearance 304 of approximately 2.25 millimeters results in abearing assembly 20 that can accommodate an angle of misalignment 306 ofup to about nine degrees between the pivot axis A of the torque tube 16and the central axis B (FIG. 6) defined by the bearing members 222, andstill provide a sufficiently low-friction support for the torque tube16.

FIGS. 11-14 illustrate another embodiment of the bearing assembly ofFIGS. 6-10 and is identified generally by the reference numeral 20A.Components of the bearing assembly 20A that are either the same orsimilar as the bearing assembly 20 have been identified with the samereference numeral except that a letter “A” has been added thereto.

As noted above with regard to bearing assembly 20, the bearing assembly20A can be supported on the pier 102, 200, or the pier 200A illustratedin FIG. 11. As shown in FIG. 11, pier 200A can have an s-shaped crosssection. In this configuration, pier 200A includes a central web portion202A, with side flanges 204A, 206A, and end with the extending flanges208A, 210A.

Piers, such as the pier 200A, having a cross section that is symmetricalwith respect to the plane in which the web portion 202A extends canavoid the torsional reactionary load created by lateral loads notedabove with regard to the pier 200. Thus, the offset 254 (FIG. 7) can beeliminated. Thus, as shown in FIGS. 11-14, the bearing housing 220A isapproximately aligned with the web portion 202A, described in greaterdetail below with reference to FIG. 14. Piers with other cross sectionscan also be used.

As shown in FIG. 12, the lower seat portion 250A including the innersurface 264A and apertures 260A can be incorporated into the upper endof the pier 200A. Optionally, the upper end of the pier 200A can alsoinclude the apertures 298A configured for protrusions 294A on thebearing member 222A.

As shown in FIGS. 12 and 13, the upper housing portion 226A can includenesting projections 300, 302 having outer surfaces 304, 306 that areshaped and positioned to next within a correspondingly shaped outersurface 310 of the bearing seat portion 250A. As such, when the upperhousing portion 226A is secured to the upper end of the pier 200A, thenesting portions 300, 302 nest with the outer surface 310 of the bearingseat portion 200A. Other configurations can also be used.

With reference to FIG. 14, as noted above, the s-shaped cross section ofthe pier 200A does not generate the torsional reactionary forces whensubjected to lateral loads in the direction of arrow F_(L) that aresubstantially aligned with the web portion 202A. For example, asillustrated in FIG. 14, the lateral load, F_(L) generated when a torquetube (not shown) presses laterally against the bearing member 222A, forexample, caused by a lateral wind acting on the torque tubes andassociated solar energy collection devices, the lateral load F_(L) isapplied generally aligned with a center axis of the bearing member 222Aalong the contact patch between the torque tube 16 and the bearingmember 222A. This point of contact would be offset by the offset 320relative to the center of the web portion 202A. However, because thelater load F_(L) is offset from the center of the web portion 202A byonly approximately 10-15% of the overall width 322 of the pier 200A, thelater load F_(L) is substantially or generally aligned with the centerof the web 202A and thus does not cause substantial or excessivetorsional or reactionary forces such as those described above withregard to the embodiments of FIGS. 6-10.

The embodiment of FIGS. 11-14 can provide a further cost savings becausethe bearing seat portion 250A can be incorporated into the upper end ofthe pier 200A thereby avoiding the additional piece used to form thelower bearing housing portion 224 (FIG. 6).

FIGS. 15-18 illustrate yet another embodiment of the bearing assembly ofFIGS. 6-10 and is identified generally by the reference numeral 20B.Components of the bearing assembly 20B that are either the same orsimilar as the bearing assembly 20 or 20A, have been identified with thesame reference numeral except that a letter “B” has been added thereto.

Most of the components of the bearing assembly 20B are the same,similar, or identical as the corresponding components of the bearingassembly 20 illustrated in FIGS. 6-10. One difference between thebearing assembly 20B and the bearing assembly 20 is that the bearingassembly 20B includes an integrated upper bearing member 223. Forexample, the integrated bearing member 223 can be considered asincluding aspects of the upper bearing member 222 and the housing upperportion 226 (FIG. 6). Optionally, in some embodiments, the integratedupper bearing member 223 can be formed from a single monolithic piece ofmaterial.

With continued reference to FIG. 15-17, the integrated upper bearingmember 223 can include aspects of the upper bearing member 222,including the inner surface 270B and optional combinations of therelated features of surface 270, described above with reference to FIG.10.

Additionally, optionally, the integrated upper bearing member 223 canalso include one or more aspects of the upper housing member 226 (FIG.6). For example, the integrated upper bearing member 223 can includeflanges 330, 332 through which apertures 260B extend for connection tothe apertures 260B on the fixture portion 230B. Optionally, theintegrated upper bearing member 223 can include a stiffening rib 334 forproviding additional structural stiffness to the integrated upperbearing member 223.

In some embodiments, the rib 334 extends from the flange 330, to theflange 332. Additionally, in some embodiments, the rib 334 can connectthe flange 330 to one of the axial edges 336 of the integrated upperbearing member 223. As such, a portion of the axial edge 336, identifiedby the reference numeral 338 forms a transition between the rib 334 andthe longitudinal edge 336 of the integrated bearing member 223. Otherconfigurations can also be used.

The integrated upper bearing member 223 can be formed from any material.In some embodiments, at least the inner surface 270B of the integratedupper bearing member 223, can be made from a reduced friction material.For example, plastic materials such as ultra high density polyethylenes,or other reduced friction materials which may or may not be impregnatedwith fibers, can be used for forming at least the inner surface 270B.

Optionally, the flanges 330 which include the apertures 260B, can bemade from a strong, hard material appropriate for facilitating fasteningwith fasteners, such as threaded fasteners. For example, portions of theintegrated upper bearing member 223 can be made from metal and co orovermolded with plastic, such as thermoplastics, with or without fiberreinforcements. In some embodiments, the entire integrated upper bearingmember 223 can be made from a single material. For example, in someembodiments, long fiber reinforced thermoplastics (LFRT) can be used forforming the entire integrated upper bearing member 223.

While at least one exemplary embodiment has been presented in theforegoing detailed description, it should be appreciated that a vastnumber of variations exist. It should also be appreciated that theexemplary embodiment or embodiments described herein are not intended tolimit the scope, applicability, or configuration of the claimed subjectmatter in any way. Rather, the foregoing detailed description willprovide those skilled in the art with a convenient road map forimplementing the described embodiment or embodiments. It should beunderstood that various changes can be made in the function andarrangement of elements without departing from the scope defined by theclaims, which includes known equivalents and foreseeable equivalents atthe time of filing this patent application.

What is claimed is:
 1. A sun-tracking photovoltaic solar collectorarray, comprising: a plurality of photovoltaic devices; a supportassembly supporting the photovoltaic devices so as to be pivotable abouta pivot axis, the support assembly comprising: at least a first pivotconfigured to support the plurality of photovoltaic devices and havingan outer surface; at least a first bearing configured to support thefirst pivot to be pivotable about the pivot axis, the first bearingcomprising at least a first reduced friction member that extends in anarc at least partway around a central axis of the first reduced frictionmember, the first reduced friction member comprising an inner surfacepositioned to slide against the outer surface of the first pivot whenthe first pivot pivots about the pivot axis, the inner surface includinga central portion and outer portions curving away from the centralportion along a direction of the central axis, wherein the outerportions have different radii of curvature than the central portion, anda width of the central portion is less than a width of the outerportions; and at least one pier supporting the bearing at a positionabove a support surface.
 2. The sun tracking photovoltaic collectorarray according to claim 1, wherein the first reduced friction memberextends around a first arc of at least about 180 degrees.
 3. The suntracking photovoltaic solar collector array according to claim 1,wherein the central portion is flat along the direction of the centralaxis and the outer portions are curved along the direction of thecentral axis.
 4. The sun tracking photovoltaic solar collector arrayaccording to claim 1, wherein an inner diameter of the inner surface issufficiently larger than an outer diameter of the outer surface of thefirst pivot such that the pivot axis of the first pivot can be axiallyoffset from the central axis of the first reduced friction member byabout nine degrees.
 5. The sun tracking photovoltaic solar collectorarray according to claim 1 wherein the first bearing comprises a bearingseat having an outer surface that is at least partially toroidal andsupports an outer surface of the first reduced friction member.
 6. Thesun tracking photovoltaic solar collector array according to claim 1additionally comprising a second bearing member, the second bearingmember having a second inner reduced friction surface with no additionalstructural member extending around an outer portion of the secondbearing member.
 7. The sun tracking photovoltaic solar collector arrayaccording to claim 1, wherein the inner surface comprises a generallyC-shaped cross-section along the direction of the central axis.
 8. Thesun tracking photovoltaic solar collector array according to claim 1,wherein the outer portions of the inner surface have a single radius ofcurvature.
 9. The sun tracking photovoltaic solar collector arrayaccording to claim 1, wherein the central portion and outer portions ofthe inner surface have multiple radii of curvature.
 10. The sun trackingphotovoltaic solar collector array according to claim 1, wherein theinner surface is convex along the direction of the central axis.
 11. Thesun tracking photovoltaic solar collector array according to claim 1,wherein the inner surface is shaped as a portion of a toroid around acentral aperture of the toroid.
 12. The sun tracking photovoltaic solarcollector array according to claim 1, wherein the first bearingcomprises a bearing seat supporting the first reduced friction member,additionally comprising a connector connecting the first reducedfriction member directly to the bearing seat.
 13. The sun trackingphotovoltaic solar collector array according to claim 12, wherein theconnector is tool-less connector.
 14. The sun tracking photovoltaicsolar collector array according to claim 13, wherein the connectorcomprises a protrusion on the outer surface of the first reducedfriction member that is configured to form a snap fit with an apertureon the bearing seat.
 15. The sun tracking photovoltaic solar collectorarray according to claim 14 additionally comprising at least a secondreduced friction member, the bearing further comprising a second bearingseat fixed relative to the first bearing seat and supporting the secondreduced friction member, the first and second reduced friction membersbeing arranged so as to extend around a circumference of the outersurface of the first pivot.